Montero Sport Brake Information

[ES_97Sport]

This is a continuation from the following thread. There's a lot of good information but not where anyone would expect to find it and I'm planning on adding more so, ...

Just did my first long trip with the Montero Sport


Mitsubishi
3000GT
91-93 TT/VR4 AWD Front - 11.625" - 13.5 lb
94-99 TT/VR4 AWD Front - 12.3125 - 17.55 lb

Gen 1 Sport
15" Sport Front AWD/4WD - 10.86" - 13.32 lb - vented
15" Sport Rear AWD/4WD - 12.406" - 19.5 lb - solid
Gen 2 Sport
15" Sport Front AWD/4WD - 10.86" - 13.32 lb - vented
15" Sport Rear AWD/4WD - 12.406" - 19.5 lb - solid
16" Sport Front AWD/4WD - 12.365" - 16 lb - vented
16" Sport Rear AWD/4WD - 12.406" - 19.5 lb - solid

Gen 1 Sport
15" Dual piston front - 1.68" dia
15" Single piston rear - 1.68" dia
Gen 2 Sport
15/16" Dual piston front - 1.68" dia
15/16" Single piston rear - 1.68" dia

GM
60s-80s Standard Duty D52 Front Rotor - 11.88" - 19.5 lb


Caliper    - Total Piston Area (sq in) Left+Right

Mitsubishi
Piston 1.68"     - 4.43
Piston 1.68" x 2 - 8.86

Ford Exploder
Piston 1.88"     - 5.55

GM D52
Piston 2" x 2    - 12.56
Piston 2.92"     - 13.39
Piston 3.15"     - 15.58


Mitsubishi Brake Pads -
Montero Sport Front pad
'97-'04 15/16" wheels
HB214
5.9"x2.27"

Montero Sport Rear pad
'00-'04 16" wheels
HB409
5.03"x1.94"


Montero Sport -
Gen 1 vacuum booster - MB895128
Gen 2 vacuum booster - ES - MR955768
Gen 2 vacuum booster - LS/XLS/Limited - MR955769


In theory, have the following brake master cylinder (BMC) options ...

1) Mitsubishi 3000GT non-turbo/Montero/Sport 1" brake master cylinder
2) Mitsubishi 3000GT VR4 w/ABS 1 1/16" brake master cylinder
3) Dodge RAM 1500 1 1/4" brake master cylinder '98-'0? RAYBESTOS MC390426
4) Dodge RAM 1500 1 1/4" brake master cylinder '97 RAYBESTOS MC390257
5) Dodge Ramcharger 5.2L 1 1/8" brake master cylinder '90-?? RAYBESTOS MC39178
6) Mitsubishi Montero/Sport 15/16" brake master cylinder

So, 15/16", 1", 1 1/8", 1 1/4". I say 'in theory' because #1, #2 and #6 are the only ones confirmed
so far. Either #4 or #5 (or maybe both) also fit as confirmed by one of the guys on 4x4Wire but I
don't know which one and he doesn't either. Some fittings need to be changed as the Dodge stuff is
SAE not Metric but adapters are available. Not a bad selection actually.



From Bimmerforums.com ...

Explanation of D.O.T. Edge Codes Located on all Brake Pads Official D.O.T. Edge Code
Coefficient of Friction (C.F.)
@ 250 F and @ 600 F Comments
EE 0.25 to 0.35 both temps 0-25% fade at 600 F possible
EF 0.25 to 0.35 @ 250 F 0.35 to 0.45 @ 600 F 2% to 44% fade at 600 F possible
FF 0.35 to 0.45 both temps 0-22% fade at 600 F possible
GG 0.45 to 0.55 Very Rare
HH 0.55 to 0.65 Carbon/Carbon only. O.K. up to 3000 F where it glows

Notes: These edge codes are located on the edge of the friction material of every brake pad
by government regulation, along with some other codes. The first letter is a grading of the
C.F. at 250 F and the second letter is a grading of the material at 600 F. Each letter grade
can actually have quite a range of C.F. But a difference in the letter grade from medium to hot
temperature could be an indicator of fade. The letters can be in any order. Therefore FE pads
fade when hot, and EF pads would not grab when cold.. Also, you should know that Steel on Steel
has a C.F. of 0.25!! (I just looked up steel friction coefficients online appears to be .6 - but
whatever) So EE pads have only marginally more torque than no pads at all! Therefore FF pads are
usually considered the minimum for a high-performance pad.


Edward

[ES_97Sport]

Required reading ...

The Brake Bible By Bill "BillaVista" Ansell

Bill's Xcel spreadsheet - puts all the math together in one place.

BillaVista Xcel Brake Spreadsheet

Montero Sport specific settings/information for Bill's spreadsheet ...

STEP 2 -
All Gen 1 & Gen 2 Standard Brakes
Front Rotor Diameter (in.) - 10.86
Rear Rotor Diameter (in.) - 12.406
Front Rotor Weight (lbs.) - 13.32
Rear Rotor Weight (lbs.) - 19.5

Gen 2 'Big' Brakes
Front Rotor Diameter (in.) - 12.365
Rear Rotor Diameter (in.) - 12.406
Front Rotor Weight (lbs.) - 16
Rear Rotor Weight (lbs.) - 19.5


STEP 3 -
Weight of vehicle (lbs.) - 3985 (*)
Max speed of vehicle (mph) - 85 (**)
Starting Temperature (*F) - 130 (***)

(*) This is the total 'road' weight of the vehicle - including passengers, fuel weight, cargo, etc.

Curb Weight Examples:
1999 Montero Sport ES 2WD - 3510
1999 Montero Sport LS/XLS 4WD - 3985
1999 Montero Sport Limited 4WD - 4145

2003 Montero Sport ES 2WD - 3835
2003 Montero Sport LS 4WD - 4215
2003 Montero Sport Limited AWD - 4340

(**) This could be a 'worst case' figure 'n' by setting the speed to the maximum from which one could expect to do a 'panic' stop from n to 0 MPH, braking in as short a distance as possible on dry, level pavement without loosing traction at any time.

(***) The temperature of the rotor prior to commencing a 'panic' stop from 'Max speed of vehicle (mph)'. This should generally be set to the normal (average) operating temperature of the rotor as seen under the most common driving conditions. Several readings using an IR Thermometer averaged together should be sufficient.


STEP 4 -
Number of calipers (each front wheel) - 1 (*)
Number of calipers (each rear wheel) - 1 (*)
Number of pistons (each front caliper) - 2
Number of pistons (each rear caliper) - 1
Caliper Design (front calipers) - 2 (*)
Caliper Design (rear calipers) - 2 (*)
Piston diameter (front) (in.) - 1.68
Piston diameter (rear) (in.) - 1.68

(*) 'Number of calipers' is always 1 and 'Caliper design' is always 2.


STEP 5 -
Rolling Radius of Tire - 14.25 (*)

(*) Inflate tires to normal operating pressure and measure from the ground to the the wheel center.

Rolling radius examples:
Gen 1 31x10.5x15/7" rim - 14.25"
Gen 2 265/70R16/7" rim  - 14.5"
35x12.5x15/8" rim       - 16.5"


STEP 5a -
Horizontal distance from front axle to C of G (in.) - 69 (*)
Wheelbase (in.) - 107.3
Vertical Height of vehicle's C of G (in.) - 32 (**)

(*) This number is an educated guess because I don't have the equipment to accurately measure this; but this number returns a brake bias of approximately 35% rear and 65% front.

(**) Draw an imaginary line between the centers of the left and right camshafts, and measure from the ground to this line.


STEP 6 -
Front
Effective Rotor Radius (in) - 4.107 (*)
Coefficient of friction between pad and rotor - 0.30 (**)

Rear
Effective Rotor Radius (in) - 5.045 (*)
Coefficient of friction between pad and rotor - 0.30 (**)

(*) All Gen 1 & Gen 2 Standard Brakes
Rotor Dia (in) - Effective Radius (in)
10.86 (front)  - 4.107
12.406 (rear)  - 5.045

Gen 2 'Big' Brakes
Rotor Dia (in) - Effective Radius (in)
12.365 (front) - 4.8595
12.406 (rear)  - 5.045

(**) Standard OEM pads appear to be edge code EE or EF. Substitute the friction coefficient from the pads if available, otherwise use 0.30 (EE) or 0.35 (EF). Its best to use an average of the range for this figure.


STEP 7 -
Pedal Effort Desired (lbs) - 75 (*)

(*) Less pedal effort will yield a more 'sensitive' pedal overall which is not necessarily desirable especially off road.


STEP 9a -
Pedal Ratio - 4 (*)

(*) Gen 1 & Gen 2 NA Montero Sport all.


STEP 9e -
Booster Multiplication - 7 (*)

(*) Gen 1 & Gen 2 NA Montero Sport 3.0/3.5L 2WD/4WD.


STEP 9h -
All Gen 1 & Gen 2 Standard Brakes
Actual MC Size (piston diameter) (in.) - 0.9375

Gen 2 'Big' Brakes
Actual MC Size (piston diameter) (in.) - 1


Edward

[ES_97Sport]

Brake master cylinder (BMC), BMC adjustment tool, booster ratios and pedal ratio information specific to the Montero Sport from a previous thread.

Brake master cylinders

Edward

[ES_97Sport]

Brake bias calculator ... (all the information required by this calculator is in the second post of this thread)

TCE Performance Products - Brake Bias Calculator

Note, the calculator DOES NOT return what it SHOULD BE, it returns WHAT IT IS based on the data entered in the calculator. Please read the notes on the web site page before using.

Edward